I have an '06 800 that is stuck in AWD. I pulled the front end apart assuming that i was going to find a broken cage, but everything looks fine. Could it be just the armature plate that is warped or magnetized?

 

could be a few things. Fluid level and/or type. The armature plate like you said, a problem with the hilliard spring ...

I would first make sure that the awd coil is not getting energized somehow by a short circuit or something. If you can verify there is no power to the coil then all you have left is mechanical. I would start by making sure fluid is correct in level and type. If that doesnt cure it it is either the armature plate or the hilliard spring i would imagine. Should also measure the verify the magnet has the correct amount of clearance with the armature plate.

 

how do the rollers and springs look?

 

There was one roller that had a very very small (hard to even see) nick in it. Everything else looked fine. I changed the oil before i had taken it apart and it was still doing the same thing.

 

Just an update...I checked the coil resistance and it was 26.5 ohms. I read in the manual that it should be between 22.8 and 25.2. Do you think that this could be the issue? What could be causing the high reading? Thanks for all of your help.

 

i wouldnt worry about that.